Caterpillar Cat D40D ARTICULATED TRUCK (Prefix 2JJ) Service Repair Manual (2JJ00001 and up).pdf

Service Repair Manual
Models
D40D, D400D
ARTICULATED TRUCK

Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: D40D ARTICULATED TRUCK 2JJ
Configuration: D40D, D400D ARTICULATED TRUCK 2JJ00001-UP (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly
D40D & D400D ARTICULATED DUMP TRUCKS VEHICLE SYSTEMS
Media Number -SENR8203-02 Publication Date -01/12/2004 Date Updated -05/12/2017
SENR82030049
Front Hoist Control Valve
SMCS - 5136-010; 5136-015; 5136-016
Remove & Install Front Hoist Control Valve
To prevent personal injury, release the pressure from the hydraulic
system before any lines are removed or disconnected.
1. Drain the hydraulic oil tank.
2. Open transmission rear cover.
3. Remove sixteen bolts (2).
4. Disconnect two tubes (1). Cap or plug immediately.
5. Disconnect two lines (6). Cap or plug immediately.
6. Remove four bolts (7).
7. Remove cotter pin (5) (hidden).
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D40D, D400D ARTICULATED TRUCK 2JJ00001-UP (MACHINE) POWERED BY...
2020/2/20
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8. Remove two bolts (3).
9. Remove hoist control valve (4). The weight of the hoist control valve is 27 kg (51 lb).
NOTE: For installation of the hoist control valve, reverse the removal steps.
10. Fill the hydraulic oil tank to the correct level, refer to the Operation & Maintenance Manual.
Disassemble Hoist Control Valve
Start By:
a. remove hoist control valve
1. Disconnect line (1) from the relief valve.
2. Remove flange (2).
3. Remove boot (3) from cover.
4. Remove bolts (4) from cover.
5. Turn the control valve body around and remove two bolts (8).
6. Remove seal retainer (5). Remove seals (6) from the valve housing.
7. Pull main control spool assembly (7) from the valve housing.
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8. Remove retainer ring (9) from the cover plate.
9. Remove cover plate (14), spring and spring retainers (18), poppet (13), detent cap (17), spring
check valve (12), cover (16), seal and spacer (11), relief valve sleeve (15) and seals and spacer
(10) from the main control valve spool (7).
10. Remove line relief valve (19) from the valve housing.
11. Poppet and spring (21) will fall out of relief valve when it is removed.
12. Remove relief valve assembly (22) from the valve housing.
13. Remove plug (20) from the valve housing.
NOTE: Inspect all O-ring seals on all relief valves and plugs.
14. Remove adjusting nut (25), jam nut (24) and plunger (23) from the body of the line relief
valve.
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15. Remove circlips (26) and (30) from the relief valve.
16. Remove plunger end (28), poppet plunger (27) and spring (29) from the relief valve.
Assemble Hoist Control Valve
1. Install spring (29), poppet plunger (27) and plunger end (28) in the relief valve.
2. Install circlips (26) and (30) on the relief valve.
3. Install plunger (23) jam nut (24) and adjusting nut (25) in the body of the line relief valve.
4. Install plug (20) in the housing.
5. Install relief valve assembly (22) in the valve housing.
6. Make sure poppet and spring (21) is installed in the relief valve assembly.
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7. Install line relief valve (19) in the valve housing.
8. Install seals and spacer (10), relief valve sleeve (15), seal and spacer (11), cover (16), spring
check valve (12), detent cap (17), poppet (13), spring and spring retainers (18) and cover plate
(14) on the main control valve spool.
9. Install retainer ring (9) from the cover plate.
10. Install main control valve spool assembly (7) in the valve housing.
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11. Install bolts (4) from cover.
12. Install boot (3) from cover.
13. Install flange (2).
14. Connect line (1) to the relief valve.
End By:
a. install hoist control valve
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 20 13:16:13 UTC+0800 2020
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2020/2/20

Shutdown SIS
Previous Screen
SENR82030050
Hoist Cylinder, Serial Number 2JJ1-Up
SMCS - 5102-010
Remove & Install Hoist Cylinder
To prevent possible personal injury, do not disconnect any hydraulic
lines until all the hydraulic pressure has been released from the system.
1. Place wooden blocks between rear suspension cradle and frame.
2. Raise the body about 300 mm (12 in) and place wooden blocks.
3. Remove two bolts (5) to lower guard group (7).
4. Attach strap to hoist cylinder (3).
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5. Disconnect two hoses (4). Cap or plug off immediately.
6. Remove two bolts (1) and (6).
7. Remove pin (2).
8. Remove pin (8).
9. Remove hoist cylinder from machine by swinging cylinder out and down. The weight of the
hoist cylinder is approximately 34 kg (75 lb).
NOTE: For installation of the hoist cylinder, reverse the removal steps.
Thu Feb 20 13:17:09 UTC+0800 2020
2/2
2020/2/20

Shutdown SIS
Previous Screen
SENR82030051
Hoist Cylinder, Serial Number 8TF1-Up
SMCS - 5102-010
Remove & Install Hoist Cylinder
Start By:
a. relieve pressure to the hoist cylinder
To prevent possible personal injury, do not disconnect any hydraulic
lines until all the hydraulic pressure has been released from the system.
1. Disconnect two hose fittings (1) from hoist cylinder (2). Cap or plug off immediately.
1/3
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2. Remove grease nipple adapter (3) and bolt (5) from pin assembly (4).
3. Attach a sling and hoist to upper end of hoist cylinder (2). Use tool (A) to remove pin assembly
(4).
4. Remove grease nipple adapter (7) and bolt (6) from lower pin assembly (8).
5. Using the hoist, lower the hoist cylinder (2) and rotate out from the truck body. Position so hoist
cylinder rests on the forks of a lift truck.
6. Use tool (A) to remove the lower pin assembly (8) from the chassis.
2/3
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7. Attach a second sling to the hoist cylinder (2). Remove the hoist cylinder from the chassis. The
weight of the hoist cylinder is 221 kg (490 lb).
NOTE: For installation of the hoist cylinder, reverse the removal steps.
End By:
a. pressurize the hydraulic system to the hoist cylinder.
Thu Feb 20 13:18:05 UTC+0800 2020
3/3
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Shutdown SIS
Previous Screen
SENR82030052
Hoist Control, Serial Number 8TF1-Up
SMCS - 5131-010
Remove & Install Hoist Control
Start By:
a. remove ether starting aid
1. Remove pin (2).
2. Remove lever assembly (1).
3. Remove collar trim (3).
Photo does not show ether aid mounting group removed
4. Remove cotter pin (6).
1/2
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5. Remove pin (5).
6. Remove lever assembly (4).
NOTE: Remove & replace two bushings if necessary.
NOTE: For installation of the hoist control, reverse the removal steps.
End By:
a. install ether starting aid
Thu Feb 20 13:19:01 UTC+0800 2020
2/2
2020/2/20

Shutdown SIS
Previous Screen
SENR82030053
Suspension Control Valve
SMCS - 7214-010; 7214-015; 7214-016
Remove & Install Suspension Control Valve
Before working on the front suspension valve, clear all personnel from
around the machine. Failure to do so could result in injury or death.
Relieve hydraulic pressure on the front suspension system by attaching
the handle assembly to suspension control valve and manually
depressing the lever assembly to relieve pressure from the front
suspension system.
1. Disconnect electrical connection (5), and hose (3) from the top of suspension control valve (2).
2. Remove two bolts (1) securing electrical harness clips.
3. Remove bolt (6) to release bracket (7) from suspension control valve (2).
4. Disconnect tube (4) from the right side of suspension control valve (2).
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5. Disconnect hose (10) from the right side suspension control valve (2).
6. Disconnect two hoses (8) from the front of suspension control valve (2).
7. Remove two bolts (9). Remove front suspension control valve (2). The weight of suspension
control valve is 26 kg (51 lb).
NOTE: For installation of the front suspension control valve, reverse the removal steps.
Disassemble Suspension Control Valve
Start By:
a. remove suspension control valve
1. Remove two bolts (2) and then remove solenoid pilot mechanism (1).
2. Remove piston (3) and cylinder (4) from the valve spool assembly.
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3. Slowly remove bolt (5) to release any potential spring tension.
4. Remove spring retainer (8), spring (7), washer (6) and spacer (9).
5. Remove bolts (10) to remove manual linkage and spool actuator (11).
6. Remove all seals (12) and valve spool (13).
NOTE: Inspect all seals on all plugs.
7. Remove plug (16), spring (15) and poppet valve assembly (14).
8. Remove plug (18) and load check valve (17).
3/6
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9. Remove plug (20) and adapter (19).
Assemble Suspension Control Valve
NOTICE
Inspect each check valve for unrestricted movement such as debris in
the passages, etc. Check the condition of all O-ring seals and back-up
rings on all check valves and plugs.
1. Install adapter (19) and plug (20).
2. Install load check valve (17) and plug (18).
3. Install poppet valve assembly (14), spring (15) and plug (16).
4/6
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4. Install valve spool (13) and install seals (12).
5. Install manual linkage and spool actuator (11) with bolts (10).
6. Install spacer (9), washer (6), spring (7) and spring retainer (8).
7. Install bolt (5).
8. Install cylinder (4) and piston (3) on the valve spool assembly.
9. Install solenoid pilot mechanism (1) and two bolts (2).
5/6
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End By:
a. install suspension control valve
Thu Feb 20 13:19:57 UTC+0800 2020
6/6
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Caterpillar Cat D40D ARTICULATED TRUCK (Prefix 2JJ) Service Repair Manual (2JJ00001 and up).pdf

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Caterpillar Cat D40D ARTICULATED TRUCK (Prefix 2JJ) Service Repair Manual (2JJ00001 and up).pdf